Endorsed by American
Designation: B 252 – 92 (Reapproved 2004)
Standard Guide for
Preparation of Zinc Alloy Die Castings for Electroplating
and Conversion Coatings1
This standard is issued under the fixed designation B 252; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.
1. Scope
1.1 This guide is intended as an aid in establishing and
maintaining a procedure for preparing zinc alloy die castings
for electroplating and conversion coatings. It is primarily
intended for the preparation of Alloys UNS Z33521 (AG-40A)
and UNS Z35530 (AC-41A) (Specification B 86) for electro-
plating with copper, nickel, and chromium (Specification
B 456).
1.2 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the
responsibility of the user of this standard to establish appro-
priate safety and health practices and determine the applica-
bility of regulatory limitations prior to use.
2. Referenced Documents
2.1 ASTM Standards: 2
B 6 Specification for Zinc
B 86 Specification for Zinc and Zinc-Aluminum (ZA) Alloy
Foundry and Die Castings
B 456 Specification for Electrodeposited Coatings of Cop-
per Plus Nickel Plus Chromium and Nickel Plus Chro-
mium
2.2 Military Standard:
MIL-S-13165C Shot Peening of Metal Parts3
3. Summary of Practice
3.1 The normal sequence of preparation steps is as follows:
(1) smoothing of parting lines; (2) smoothing of rough or
defective surfaces, if necessary; (3) buffing, if necessary; (4)
precleaning and rinsing; (5) alkaline electrocleaning and rins-
ing; (6) acid dipping and rinsing; and (7) copper striking.
1
This guide is under the jurisdiction of ASTM Committee B08 on Metallic and
Inorganic Coatings and is the direct responsibility of Subcommittee B08.02 on Pre
Treatment.
Current edition approved April 1, 2004. Published May 2004. Originally
approved in 1951. Last previous edition approved in 1998 as B 252 – 92 (1998).
2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website.
3
Available from Standardization Documents Order Desk, Bldg. 4 Section D, 700
Robbins Ave., Philadelphia, PA 19111-5094, Attn: NPODS.
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Electroplaters’ Society
Endorsed by National
Association of Metal Finishers
4. Significance and Use
4.1 The performance and quality of electroplated or
conversion-coated zinc alloy die casting depends upon the
surface cleanliness and condition. Various metals are electro-
plated or conversion coatings are established on zinc alloys for
decorative or engineering finish. The common electroplates
applied are usually copper, nickel, and chromium for decora-
tive and functional uses. The common conversion coatings
applied are phosphates, chromates, and anodized coatings.
Electroplated zinc die castings and conversion coatings on zinc
die castings are used in many industries such as the marine,
automotive, plumbing fixtures, and appliance industries.
5. Composition and Characteristics of Zinc Alloy Die
Castings
5.1 The alloys used in the manufacture of zinc alloy die
castings are made with special high-grade zinc conforming to
Specification B 6, alloyed with about 4 % of aluminum, 0.04 %
of magnesium, and either 0.25 (max) or 1.0 % copper (Alloys
UNS Z33521 and UNS Z35530). Impurities such as lead,
cadmium, tin, and iron are held at or below the specified low
levels in Specification B 86.
5.2 Die castings made of Alloys UNS 233521 and UNS
235530 are usually dense and fine grained but do not always
have smooth surfaces. Defects sometimes encountered in the
surface layers include cracks, crevices (cold shut), skin blisters,
and hemispherical pores. Burrs are usually left at parting lines
where fins and gates are removed by die trimming.
5.3 Cast surfaces are frequently contaminated with parting
compounds applied at frequent intervals to die surfaces to
facilitate the ejection of the castings and with water-soluble
oils added to quenching tanks for corrosion inhibition.
5.4 Zinc alloy die castings are chemically active and are
dissolved or etched during prolonged contact with concentrated
solutions of many mineral or organic acids or strongly alkaline
solutions with a pH greater than 10. Immersion periods in such
solutions should be of short duration to avoid roughening.
 B 252 – 92 (2004)
6. Smoothing of Parting Lines
6.1 Parting lines are smoothed by (1) mechanical polishing
with abrasive-coated wheels or belts, (2) tumbling with abra-
sive media, or (3) vibration with abrasives.
6.2 Abrasives with a size range of 220 to 300 mesh glued on
cloth wheels or continuous cloth belts that run over flexible
back-up wheels are usually used for mechanical polishing of
parting lines. Wheel diameters range from 5 to 40 cm,
depending on the complexity of the shape. Wheels are rotated
with a minimum peripheral speed of 2500 m/min. A peripheral
speed of 2100 m/min should not be exceeded with belts. Lower
speeds of the order of 1100 to 1400 m/min are fairly common
for small die castings polished on small diameter wheels.
Abrasive belts should not be used dry but should be lubricated
with a small amount of grease. Die castings usually are handled
individually to polish parting lines smooth. This may require
30 s or less for small castings, and sometimes 5 or 6 min for
larger ones.
6.3 Tumbling in horizontal barrels, loaded with abrasive
stones such as limestone, preformed and fused aluminum
oxide, ceramic shapes or abrasive-loaded plastic chips, and a
lubricant such as soap or detergent solution, removes parting-
line burrs from die castings in 4 to 12 h. The barrels may be
rotated at 4 r/min. Higher speeds reduce the time cycles and
costs, but also increase the danger of impingement of parts
against zinc surfaces. A hexagonal barrel with a capacity of 0.5
m3 can be loaded with 450 kg of abrasive stones or chips and
90 kg of zinc die castings.
6.4 Vibration in a bed of resin-bonded abrasive chips
removes parting-line burrs, typically in 1 to 4 h. Frequencies
range from 700 to 2100 cpm and amplitudes from 0.8 to 6.4
mm. A vibrating tub with a capacity of 0.5 m3 can be loaded
with about 900 kg of abrasive media and 180 kg of zinc die
castings. A dilute solution of detergent or soap is continuously
metered through the bed of media and parts to keep their
surfaces clean and maximize surface smoothing. Parting lines
may be mechanically polished before vibratory processing
when a large amount of flash must be removed.
7. Smoothing of Rough or Defective Surfaces
7.1 Rough or defective surfaces are smoothed by (1) me-
chanical polishing on rotating wheels or continuous, abrasive-
coated belts, (2) spin finishing, (3) vibratory finishing, or (4)
controlled shot peening. Fissures, skin blisters, and other
defects with a depth of 25 to 50 µm can usually be erased with
these metal-removal methods. Deeper defects are infrequent.
7.2 Mechanical polishing for smoothing rough or defective
surfaces is similar to mechanical polishing for smoothing
parting line areas (see 6.2). Parting lines and rough or defective
surfaces are frequently polished by the same operator. If
polishing is mechanized to advance die castings attached to a
conveyor through successive belts or wheels to polish different
areas, a manual operation may be required later to complete the
smoothing of parting lines if they are too curved. The finish
ranges from 0.2 to 0.6 µm, depending on the abrasive and the
pressure.
7.3 Smoothing by spinning in abrasives is accomplished by
attaching die castings to spindles or drums rotated with a
2
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peripheral speed of about 600 m/min in a slurry of abrasive
material such as ground corn cobs or nut shells mixed with a
small amount of grease or other lubricant. Times usually range
from 5 to 10 min and the finish from 0.1 to 0.2 µm, depending
on the abrasive.
7.4 Vibrating tubs loaded with plastic chips (such as poly-
urethane) impregnated with an abrasive (such as aluminum
oxide) smooth the surfaces of die castings in 2 to 4 h when
frequencies are in the range of 1700 to 2100 cpm and
amplitudes are adjusted to 3.2 to 6.4 mm. Vibratory machines
produce a finish of 0.15 to 0.25 µm, with a cutting rate of 5
µm/h. A smoother finish of 0.075 to 0.125 µm can be obtained
with plastic media containing finer abrasive, which removes
metal at a slower rate. Media and zinc parts are usually loaded
with a ratio of 5:1 or 6:1. Surface gouges may occur with a
smaller ratio.
7.5 Controlled shot peening will plastically deform and
densify the casting surface and near-surface layers. Shot
peening can seal surface pores, which can create problems in
electroplating and conversion coating. The process is described
in MIL-S-13165C. The process is also effective in removing
fins, burrs, and flash from the surface. The casting configura-
tion, including the smallest size radii and wall thickness, as
well as the required finish and contamination limits, will
dictate the proper selection of peening media, shot size,
intensity, and coverage, as is detailed in MIL-S-13165C.
8. Buffing
8.1 Die castings are buffed to produce a mirror-like finish,
suitable for plating with conventional solutions, when good
leveling plating solutions are not available. Buffing can be
omitted, however, for die castings which have good surfaces or
which can be uniformly polished to a finish of 0.25 µm, if
solutions with good leveling power are used for plating copper
and nickel.
8.2 Die castings are buffed on cloth wheels rotated at a
peripheral speed not exceeding 2150 m/min. Slower speeds, of
the order of 1100 to 1600 m/min, are used for small die
castings. Buffing compounds should be made with a binder that
is readily emulsified or saponified during alkaline cleaning.
The abrasive may be tripoli (amorphous silica) or lime, mixed
with about 25 % of tallow or other lubricants. Compounds
suspended in a liquid are preferred for automatic buffing
machines that advance die castings through a succession of
buffs of varying diameter and width, which individually
smooth different surface areas. Buffs are usually made of cloth
with a thread count of 34 to 37/cm. A finish of 0.025 to 0.05 µm
can be produced by buffing. The smoothing rate is influenced
by the temperature of the metal surface (faster at approximately
150°C than at lower temperatures).
8.3 After buffing, surfaces with impacted buffing compound
can be improved by passing them over a dry wheel to remove
buffing compound. This will reduce the demand placed on the
precleaning solution.
9. Precleaning and Rinsing
9.1 It is strongly recommended that the preliminary removal
of most of the buffing compound and other soil in a precleaning
operation be done as soon as possible after buffing and
 B 252 – 92 (2004)
polishing. Most buffing compounds become substantially more
difficult to remove after aging several days.
9.2 There are several methods by which soils can be
removed from zinc die castings prior to final alkaline electro-
cleaning. Generally speaking, these fall into three main classes:
solvent degreasing, emulsion cleaning, and cleaning with
aqueous base detergents.
9.2.1 Solvent Degreasing—Before considering the use of
solvent degreasing, federal and state safety and environmental
laws and regulations should be consulted. Many of the com-
monly used solvents are now being banned from use. Exposure
to their vapors (VOC) is being strictly regulated for health,
safety, and environmental reasons. Current safe exposure levels
for various solvents should be obtained before use. Cold
solvents, such as mineral spirits, methylene chloride, trichlo-
roethylene, perchloroethylene and trichloroethane, are used
with brushing to loosen packed buffing compound, but this
method usually is not practical for mass production conditions.
Simple dipping in cold solvent is often ineffective. Vapor
degreasing4 with trichloroethylene or perchloroethylene is
widely practiced. Often the buffed die castings are sprayed
with, or immersed in, hot solvent for mechanical removal of
heavy soil deposits. This is followed by condensation of hot,
clean solvent vapors on the work; this removes the last traces
of grease and compound. The method is very effective,
provided adequate measures are taken to remove the very fine
abrasive and metallic particles from the work. Trichloroethyl-
ene and perchloroethylene are nonflammable as used in vapor
degreasing and still must be used in systems designed to
protect personnel from inhalation of vapors. Suppliers of
solvents should be consulted as to the safety of a given
installation.
9.2.1.1 All federal, state, and local regulations for the
disposal of solvents should be followed.
9.2.2 Emulsion Cleaning:
9.2.2.1 Impacted buffing compound may be loosened, and to
some extent removed, by immersion in various hydrocarbon-
water emulsions. These emulsions are available in several
forms, including unstable emulsions (diphase cleaners), invert
type emulsions, mixtures of emulsions and alkaline cleaners,
and stable emulsions. Such emulsion cleaners usually have a
suitable hydrocarbon base such as kerosene or a higher
flashpoint solvent to which is added emulsifiers, soaps, and
inhibitors to prevent etching of the die castings. The pH of the
emulsion cleaner should be kept between 7 and 10 to avoid
damage to the castings.
9.2.2.2 These emulsions normally are used hot, about 80°C,
as a soak, sometimes with agitation, for about 2 to 5 min. A
warm water spray rinse should follow the emulsion soak
cleaning. Buffing compound not removed in the emulsion soak
is sufficiently softened so that it is easily removed in an
alkaline spray wash operation that normally follows.
9.2.2.3 Emulsion cleaning is an effective method for remov-
ing buffing compound. Its principal disadvantage is the danger
of carryover of hydrocarbon solvent into plating baths because
4
ASTM Committee D26 Manual on Vapor Degreasing, MNL2, ASTM, Phila-
delphia, PA.
3
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of incomplete rinsing. For this reason, it is very important that
proper alkaline cleaning and rinsing follow to ensure solvent
removal from blind holes, defects in rack coatings, and
recesses.
9.2.2.4 All federal, state, and local regulations for the use
and disposal of solvents should be followed.
9.2.3 Aqueous Base Detergents—In recent years, hot mix-
tures of emulsifiers and surfactants (wetting agents), some-
times combined with mild alkaline phosphates or borates, are
used for soak cleaning to soften and remove buffing compound.
Combining soak cleaning with ultrasonics is particularly effec-
tive on impacted buffing compound. Such detergent soaks
should be followed by spray cleaning with an alkaline cleaner.
If a spray cleaning step is not needed, then the soak cleaning
step should be followed by a spray rinse with warm water
before electrocleaning. Sometimes conventional alkaline soak
cleaners are used for precleaning die castings with little or no
buffing compound on them. These alkaline cleaners must be
mild and inhibited since strong alkali will attack the castings.
9.3 Power Spray Alkaline Washing—Alkaline spray clean-
ers are widely used, during the initial cleaning operation or
following initial presoaks in emulsions, solvents, or detergents.
This is accomplished with conveyerized units equipped with
washing, draining, rinsing, and draining sections. The solution
heated to a temperature range of 50 to 80°C is sprayed with a
pressure of 170 to 205 kPa through nozzles on 20 to 30 cm
centers in the washing area. A typical solution may contain 10
g/L of mixed alkalies such as trisodium phosphate, sodium
tripolyphosphate, sodium metasilicate, and sodium bicarbonate
and not more than 1 g/L sodium hydroxide. The solution
should also contain not more than 0.2 g/L of a low-foaming or
non-foaming surfactant. In a typical precleaning cycle, a 1 to 2
min washing period is followed with a 1⁄2 to 1 min draining
period, a 1⁄2 to 1 min water rinse with spray nozzles and a final
draining period of 1⁄2 to 1 min. Proprietary alkaline spray
cleaners are available for this application.
10. Alkaline Electrocleaning and Rinsing
10.1 Electrocleaning is necessary for completing the re-
moval of oil, grease, and soil, and to ensure good electroplate
adhesion. Anodic cleaning is usually selected for zinc alloys in
preference to cathodic cleaning. Anodic current densities
usually range from about 1.6 to 3.2 A/dm2. Time cycles vary
from 25 to 45 s.
10.2 A typical solution for anodic cleaning contains 30 to 40
g/L of mixed alkalies such as trisodium phosphate and sodium
metasilicate, 0.5 g/L of a low-foaming surfactant, and not more
than 0.5 g/L of sodium hydroxide and is heated to 70 to 82°C.
Proprietary products for anodic cleaning are available. Lower
temperatures may be required if time cycles must be prolonged
for more than 45 s, or if the transfer time from the electro-
cleaner to the first rinse is more than about 30 s. Operating an
anodic electrocleaner at too dilute concentrations may over
etch the castings.
10.3 A cycle including a warm water rinse, a cold water
rinse, and a water spray rinse is recommended after alkaline
electrocleaning. The rinses should be agitated with air to dilute,
as much as possible, the concentration of alkaline solution in
blind holes, grooves, and other surface indentations and
 B 252 – 92 (2004)
cavities. Alkaline solution entrapped in surface crevices and
pores will become sites for process blisters if alkaline cleaner
concentrations are not reduced to very low levels by agitated
cold water rinsing. Rinse water containing a high concentration
of dissolved minerals should be avoided.
10.4 Electrocleaning may not be required for the application
of conversion coatings.
11. Acid Dipping and Rinsing
11.1 An acid dip must follow alkaline cleaning, to remove
zinc oxidation products and trace amounts of alkaline com-
pounds carried over from the cleaning operations due to the
inadequate rinsing. The strength must be adjusted to the time of
immersion. A solution containing 0.25 to 0.75 % by weight of
sulfuric acid is frequently used for time cycles of 25 to 45 s, at
room temperature. A solution of citric acid is a safe alternative.
All acids used should be removed by thorough rinsing before
electroplating or applying a conversion coating. Excessive
exposure to stronger acid solutions can cause etching and
dissolution of the metal.
11.2 The acid dip should remove all traces of black films or
loosely adherent smut. For die castings prone to smut, includ-
ing alloys containing more than about 0.25 % copper, the acid
solution can be ultrasonically agitated; this effectively prevents
the retention of smut on the surface.
11.3 A succession of two agitated overflow rinses and a
water spray rinse is suggested after acid dipping. A final water
rinse should use deionized spray water, which can be recycled
for use in an initial rinsing stage. Acid solution must be
completely removed from crevices and pores, to avoid blisters
that may otherwise occur during or soon after plating. Crevices
and pores in grooves and other surface indentations are
common sites for process blisters if rinsing after acid dipping
is incomplete.
11.4 Electrocleaning may not be required for the application
of conversion coatings.
12. Copper Striking
12.1 A copper strike applied in a cyanide copper solution is
normally the first plating step for all die castings to be
electroplated with nickel and chromium. The thickness of the
strike should be at least 1.0 µm for die castings that will be
subsequently plated with bright copper in high-temperature
cyanide solutions and at least 5.0 µm for die castings that will
be plated with nickel after copper striking. A thickness of 3.0
to 4.0 µm is recommended for die castings that will be
subsequently electroplated with bright, leveling copper in
copper sulfate-sulfuric acid solutions.
12.2 Solutions containing 20 to 25 g/L of copper cyanide,
10 to 20 g/L of free sodium cyanide, and 15 to 75 g/L of
sodium carbonate are customary for strike solutions. A few
formulations include the molar equivalents of potassium cya-
nide in place of sodium cyanide. Others contain 3.8 to 7.5 g/L
of sodium hydroxide in addition to the major constituents. In
many of the formulations, use is made of addition agents that
reduce hexavalent chromium, aid in anode corrosion, and
refine the grain structure. Cathode current densities normally
range from 2.7 to 6.5 A/dm2 and solution temperatures from 50
to 57°C. Cyanide solutions containing a higher concentration
of copper cyanide and operated at a higher temperature should
be avoided because of the danger of blister formation.
12.3 The average cathode current density must be balanced
with the free sodium cyanide and the temperature of the
solution to prevent burning at edges and other high-current-
density areas. With an average cathode current density of 2.7
A/dm2, the cathode current efficiency varies from 30 to 60 %
for strike plating. A high temperature, a high copper cyanide
concentration, and a low-free cyanide concentration, within the
limits given in 12.2, favor high efficiency. Ultrasonic agitation
has been proposed for increasing cathode efficiency, the
covering power in recessed areas, and improving the density of
the copper deposit. Ultrasonic agitation has been reported as an
important condition for copper striking in cyanide-free solu-
tions prepared with potassium pyrophosphate, copper pyro-
phosphate and potassium citrate, prior to bright copper plating
in acid sulfate solutions.5
12.4 High-purity copper anodes are recommended for cop-
per cyanide strike solutions. Solutions should be continuously
filtered to avoid the inclusion of small particles that nucleate
nodules during subsequent plating operations.
5
Safranek, W. H., and Miller, H. R., “Copper Plating on Zinc Die Castings,”
Plating, 1968, pp. 233–237.

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